Corrosion inhibitors for a fluid

ABSTRACT

One or more methods for inhibiting corrosion in a fluid that contain a composition with a specified generic formula are disclosed. The fluid can be contained in an oil or gas pipeline or refinery.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part to U.S. patent application Ser. No. 12/245,806, which was filed on Oct. 6, 2008, now allowed, from which filing priority is hereby claimed and the disclosure of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The field of the invention pertains to corrosion inhibitors for a fluid, e.g. a fluid in an oil and gas pipeline or refinery.

BACKGROUND OF THE INVENTION

Corrosion of metal surfaces in a fluid has long been a problem for the oil and gas industry. It is well known that during the production of oil and gas several other corrosive components are present such as brines, organic acids, carbon dioxide, hydrogen sulfide, and microorganisms. These aggressive constituents can cause severe corrosion to metal pipes, which are often made of low-alloy steels. This problem is even more troublesome in deep-sea operations where replacement of corroded equipment is difficult and costly. Therefore, it is common practice to employ corrosion inhibitors during the production, transportation, storage, and separation of crude oil and natural gas.

Corrosion inhibitors are usually surface-active compounds that form protective coatings on the surface of metal components, which come in contact with corrosive environments, and thus suppress corrosion. Common corrosion inhibitors are composed of amines, condensation products of fatty acids with polyamines, e.g. imidazolines, or quaternary ammonium compounds. Among the most frequently used corrosion inhibitors in crude oil and natural gas extraction are imidazoline derivatives. Alternative corrosion inhibitors that can be used alone or in combination with known corrosion inhibitors are being sought by the industry.

SUMMARY OF THE INVENTION

The present invention provides for a method of inhibiting corrosion in a fluid comprising: adding to the fluid an effective corrosion inhibiting amount of a synergist, a synergist when H₂S is present in the fluid, or no synergist when H₂S is present in the fluid, and a composition comprising the following formula and optionally salts thereof:

where R₁ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; or H;

-   where R₂ is a C₁ to C₂₂ alkyl; -   where R₃ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; or H; -   where X⁻ is a halogen or a carboxylate and wherein X⁻ is only     present when both R₁ and R₃ are present; -   where Y═(CH₂)_(n), wherein n is 1 to 8; and -   wherein R₃ and R₁ cannot be hydrogen at the same time.

The present invention also provides for a method of inhibiting corrosion in a fluid comprising: adding to the medium an effective corrosion inhibiting amount of a synergist, a synergist when H₂S is present in the fluid, or no synergist when H₂S is present in the fluid, and a composition comprising the following formula and optionally salts thereof:

where R₁ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; or H;

-   where R₂ is C_(n)H_(2n+1), wherein n=1 to 22; -   where X═Cl, Br, or I

DETAILED DESCRIPTION OF THE INVENTION

The methodology described above can have various embodiments.

In one embodiment, the compositions contain various amounts of different compositions that fall within the claimed formula.

In another embodiment, the alkyl groups of R₁ and/or R₂ are linear, branched, cyclic, and/or unsaturated.

In another embodiment, R₃ is a methyl or ethyl group. In further embodiment, R₃ has a linear conformation.

In another embodiment, the halogen is chlorine, bromine, or iodine. The halogen is in ionic form when it is associated with the composition.

In another embodiment, Y═(CH₂)_(n), wherein n is 1 to 4, optionally wherein Y is linear or branched. When n=1, Y can not be branched.

In another embodiment, R₁ is a C₄-C₆ alkyl.

In another embodiment, R₂ is a C₆-C₁₂ alkyl.

In another embodiment, the composition comprises the following formula and optionally salts thereof:

In another embodiment, the composition comprises the following formula:

In another embodiment, the composition comprises the following formula:

The compositions encompassed by this disclosure are applied to a fluid that contains various levels of salinity.

In one embodiment, the fluid that has a salinity of 1% to 20% weight/weight (w/w) total dissolved solids (TDS).

The fluid to which the composition is applied to can contain various levels of water cut. One of ordinary skill in the art would interpret water cut to mean the percentage of water in a composition containing an oil and water mixture.

In one embodiment, the water cut is from 0% to 100% volume/volume (v/v).

In another embodiment, the water cut is from 1% to 60% v/v.

Various synthesis methodologies, which can be appreciated by one of ordinary skill in the art, can be utilized to make the claimed compositions. These compositions are then utilized in methods of inhibiting corrosion. The compositions can be made in the presence of a synergist.

In one embodiment, a composition is prepared by reacting an alkyl acrylate with 1-methylpiperazine.

In a further embodiment, the acrylate is a lauryl acrylate.

In another embodiment, the composition contains a quaternary ammonium salt prepared by reacting dodecyl 3-(4-methylpiperazine-1-yl) with an alkyl or a benzyl halide.

The compositions of this invention can contain one or more additional chemistries. Various formulations can be appreciated by one of ordinary skill in the art and can be made without undue experimentation. For example, crude mixtures of varied alkyl distributions are encompassed by this invention.

In one embodiment, the composition further comprises one or more hydrate inhibitors.

In another embodiment, the composition further comprises one or more thermodynamic hydrate inhibitors, one or more kinetic hydrate inhibitors, one or more anti-agglomerants, or a combination thereof.

In another embodiment, the composition further comprises one or more asphaltene inhibitors, paraffin inhibitors, corrosion inhibitors, scale inhibitors, emulsifiers, water clarifiers, dispersants, emulsion breakers, or a combination thereof.

In another embodiment, the composition further comprises one or more polar or non-polar solvents or a mixture thereof.

In another embodiment, the composition further comprises one or more solvents selected from isopropanol, methanol, ethanol, heavy aromatic naptha, toluene, ethylene glycol, ethylene glycol monobutyl ether (EGMBE), diethylene glycol monoethyl ether, xylene, or a combination thereof.

The fluid in which the compositions and/or formulations are applied to can be contained in many different types of apparatuses, especially those that transport a fluid from one point to another point, e.g. in one embodiment, the fluid is contained in an oil and/or gas pipeline.

In another embodiment, the fluid in which the compositions and/or formulations are applied to is in contact with many different types of surfaces that are capable of corrosion, e.g. those in an oil and gas pipelines/refineries, e.g. separation vessels, dehydration units, gas lines, and pipelines; and cooling water systems.

In another embodiment, the compositions and/or formulations are applied to industrial water systems and/or municipal water systems.

The compositions of the present disclosure and/or formulations thereof can be applied to a fluid in various ways that would be appreciated by of ordinary skill in the art. One of ordinary skill in the art would appreciate these techniques and the various locations to which the compositions or chemistries can be applied.

In one embodiment, the compositions and/or formulations are pumped into the oil/gas pipeline by using an umbilical line. In a further embodiment, capillary injection systems can be utilized to deliver the surfactants, in this case corrosion inhibitors. U.S. Pat. No. 7,311,144 provides a description of an apparatus and methods relating to capillary injection, which is herein incorporated by reference.

Various dosage amounts of a composition and/or formulation can be applied to the fluid to control corrosion. One of ordinary skill in the art would be able to calculate the amount of corrosion inhibitor for a given situation, e.g. content of fluid, without undue experimentation.

In one embodiment, the dose range for the corrosion inhibitor that is applied to fluid, e.g. fluid contained in an oil/gas pipeline, is between 0.1% vol to 2% vol based on water cut.

Various types of synergists may be added to the fluid in combination with the composition(s) described above. One of ordinary skill in the art could appreciate how to formulate a synergist and the composition.

In one embodiment, a synergist, a synergist when H₂S is present in the fluid, or no synergist when H₂S is present in the fluid is added to the fluid with the compositions described above.

In another embodiment, the synergist can be a mercaptoethanol, e.g. 2-mercaptoethanol.

In another embodiment, the synergist formulation contains 3.5% v/v of 2-mercaptoethanol and 20% actives of the corrosion inhibitor composition described above.

In another embodiment, the synergist is a sulfur-containing synergist.

In another embodiment, the synergist contains a thiosulfate.

The examples are not meant to be limiting.

EXAMPLE SECTION I. Synthesis Strategies For Corrosion Chemicals A. Synthesis of dodecyl 3-(4-methylpiperazine-1-yl)propanoate:

In a 40-mL scintillation vial, 12.0 g (0.05 moles) of lauryl acrylate are charged followed by the slow addition of 5.0 g (0.05 moles) of 1-methyl piperazine. The mixture is agitated using a magnetic stirrer bar and heated to 85° C. for at least 16 hours using a heating block. The final product is a light brown liquid at ambient temperature. Complete conversion is apparent from the lack of olefin protons in the ¹H-NMR spectra. ¹H-NMR (300 MHz, CDCl3): δ 3.83 (t, 6.6 Hz, 2H), 2.45 (t, 7.3 Hz, 2H), 2.24 (m, 10H), 2.02 (s, 3H), 1.38 (t, 6.8 Hz, 2H), 1.03 (m, 18H), 0.65 (t, 7.1 Hz, 3H). ¹³C-NMR (75 MHz, CDCl3): δ 171.78, 63.92, 54.64, 53.12, 52.39, 45.53, 31.93, 31.45, 29.19, 21.17, 29.12, 29.08, 28.89, 28.80, 28.20, 25.47, 22.20, 13.63.

B. Synthesis of 1-butyl-4-(3-(dodecyloxy)-3-oxopropyl)-1-methylpiperazine-1-ium bromide:

In a 100-mL round bottom flask, 5.0 g (0.015 moles) of dodecyl 3-(4-methylpiperazine-1-yl)propanoate and 7.3 g (0.044 moles) of butyl bromide are combined with 10 mL of isopropyl alcohol. This solution is heated to reflux overnight. Thin layer chromatography (TLC) was used to monitor the progress of the reaction with 1:1 methanol/toluene as a mobile phase and iodine to reveal the components on the plate. After the reaction is complete, the solvent and excess of butyl bromide are evaporated under vacuum. Finally, the resulting solid is dried under vacuum at 120° C. ¹H-NMR (300 MHz, CDCl3): δ 3.92 (t, 5.9 Hz, 2H), 3.76 (m, 2H), 3.56 (m, 4H), 3.35 (s, 3H), 2.91 (m, 6H), 2.46 (t, 6.6 Hz, 2H), 1.67 (m, 2H), 1.47 (m, 2H), 1.12 (m, 24H), 0.74 (m, 6H). ¹³C-NMR (75 MHz, CDCl3): δ 170.98, 64.61, 59.14, 51.84, 45.88, 31.44, 31.28, 30.81, 29.18, 29.16, 29.13, 29.08, 28.87, 28.81, 28.11, 25.50, 25.43, 22.21, 21.96, 21.60, 13.66, 13.49.

Examples 1-2, described below, were prepared by reacting I-ethyl piperazine with various alkyl acrylates. Specifically, Examples 1-2 are quaternary ammonium salts prepared from the reaction of the tertiary amine and 1-bromobutane in isopropyl alcohol at a concentration of 80% w/w solids. After the reactions were completed, as determined by TLC, the final product was diluted to 60% w/w active ingredient with methanol.

Example n R₁ X Solvent 1 8 (branched, 2-ethyl hexyl) —C4H9 Br IPA/MeOH 2 12 —C4H9 Br IPA/MeOH

II. Experimental Section A. Composition Of Corrosion Inhibitor

where R₁ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; or H;

-   where R₂ is C_(n)H_(2n+1), wherein n=1 to 22; -   where X═Cl, Br, or I

B. Sample Preparation

Each of the examples were prepared by dissolving the corrosion inhibitor to a 20% active into isopropanol and formulating it with a mercaptan synergist, 2-mercaptoethanol (3.5% 2-mercaptoethanol; other levels of synergist can be used, but this is the amount used for the experiments). Each of the examples exhibited solubility in isopropanol and was tested in a wheel box test. This test provides an indication of how a corrosion inhibitor will perform over a range of dosages.

C. Wheel Box Test Procedure

In order to test each of the examples, wheel box testing from NACE (National Association of Corrosion Engineers) publication ID182 (December 1982) were performed. The wheel box test is a test that is often used in the field of corrosion to compare the performance of a corrosion inhibitor to another. The following standard set of conditions were used to test corrosion inhibitor performance:

-   -   a. Temperature=176° F.;     -   b. Oil=10% LVT-200;     -   c. Brine=90% ASTM Seawater brine;     -   d. CO₂ Saturated;     -   e. Test Duration=24 hrs; and     -   f. Inhibitor Dosage=5, 10, 25, 50, 100 ppm based on total fluids

The performance of the corrosion inhibitors was evaluated relative to an average corrosion rate of three untreated samples. These untreated bottles exhibit much higher corrosion rates than the treated bottles. This allows the corrosion inhibitors to be evaluated by their relative percent protection. As can be seen below, each of the above examples exhibits performance at dosages as low as 5 ppm and many perform increasingly well as the dosages approach 100 ppm.

D. Examples

Example R₂ R₁ X 1 —C₁₂H₂₅ None None 2 —C₁₂H₂₅ —C₄H₉ Br 3 —C₁₂H₂₅ —C₆H₁₃ Br 4 —C₁₂H₂₅ Benzyl Cl

E. Corrosion Inhibition Results/Performance

Tables 1 to 4 show the results from the wheel box testing done for Examples 1 to 4. Example 1 is the only surfactant tested that does not contain a quaternary ammonium salt. This compound demonstrated good percent protection at low concentration (5-10 ppms), as well as at higher concentrations (25 to 100 ppms).

TABLE 1 Wheel Box testing results for corrosion inhibition using Example 1 at various concentrations. Concentration, ppm % Protection 5 35 10 46 25 49 50 49 100 55

Example 2 showed a minimal protection at low concentrations of chemical, but as the concentration is increased to 25 ppm, the protection suddenly jumps from 3% to 70%. The corrosion inhibition continued increasing as the concentration of surfactant was increased from 25 to 50ppms. The best performance is observed at 100 ppm with an 83% protection.

TABLE 2 Wheel Box testing results for corrosion inhibition using Example 2 at various concentrations. Concentration, ppm % Protection 5 2 10 3 25 70 50 78 100 83

Example 3 shows significantly better protection than Example 2 at concentrations of 10 ppm or lower. Nevertheless, at 25 ppm to 100 ppm Examples 2 and 3 have very similar corrosion inhibition performance, respectively. The best protection observed for Example 3 is 84% at a concentration of 100 ppm.

TABLE 3 Wheel Box testing results for corrosion inhibition using Example 3 at various concentrations. Concentration, ppm % Protection 5 14 10 40 25 78 50 84 100 84

The best overall performance is obtained with Example 4. Excellent protection is observed at both low and high concentrations of inhibitors. At a just 5 ppm concentration, 44% protection is observed while at 100ppm the corrosion inhibition obtained is 85%.

TABLE 4 Wheel Box testing results for corrosion inhibition using Example 4 at various concentrations. Concentration, ppm % Protection 5 44 10 60 25 78 50 80 100 85 

1. A method of inhibiting corrosion in a fluid comprising: adding to the medium an effective corrosion inhibiting amount of a synergist, a synergist when H₂S is present in the fluid, or no synergist when H₂S is present in the fluid, and a composition comprising the following formula and optionally salts thereof:

wherein R₁ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; acrylate or H; wherein R₂ is a C₁ to C₂₂ alkyl; wherein R₃ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; or H; wherein X⁻ is an anion, halogen, sulfate or a carboxylate and wherein X⁻ is only present when both R₁ and R₃ are present; wherein Y=(CH₂)_(n), wherein n is 1 to 8; and wherein R₃ and R₁ cannot be hydrogen at the same time.
 2. The method of claim 1, wherein the alkyl groups of R₁ and/or R₂ are linear, branched, and/or cyclic.
 3. The method of claim 1, wherein R₃ is a methyl or an ethyl group.
 4. The method of claim 1, wherein the halogen is chlorine, bromine, or iodine.
 5. The method of claim 1, wherein R₁ is a C₄-C₆ alkyl.
 6. The method of claim 1, wherein R₂ is a C₆-C₁₂ alkyl.
 7. The method of claim 1 wherein the composition comprises the following formula and optionally salts thereof:


8. The method of claim 1 wherein the composition comprises the following formula:


9. The method of claim 1 wherein the composition comprises the following formula:


10. The method of claim 1, wherein the composition further comprises one or more hydrate inhibitors.
 11. The method of claim 1, wherein the composition further comprises one or more thermodynamic hydrate inhibitors, one or more kinetic hydrate inhibitors, one or more anti-agglomerants, or a combination thereof.
 12. The method of claim 1, wherein the composition further comprises one or more asphaltene inhibitors, paraffin inhibitors, corrosion inhibitors, scale inhibitors, emulsifiers, water clarifiers, dispersants, emulsion breakers, or a combination thereof.
 13. The method of claim 1, wherein the composition further comprises one or more polar or nonpolar solvents or a mixture thereof.
 14. The method of claim 1, wherein the composition further comprises one or more solvents selected from isopropanol, methanol, ethanol, heavy aromatic naptha, toluene, ethylene glycol, EGMBE, diethylene glycol monoethyl ether, xylene, or a combination thereof.
 15. A method of inhibiting corrosion in a fluid comprising adding to the medium an effective corrosion inhibiting amount of a synergist and a composition prepared by reacting an alkyl acrylate with 1-methylpiperazine.
 16. The method of claim 15 wherein said acrylate is a lauryl acrylate.
 17. A method of inhibiting corrosion in a fluid comprising: adding to the medium an effective corrosion inhibiting amount of a synergist, a synergist when H₂S is present in the fluid, or no synergist when H₂S is present in the fluid, and a composition comprising the following formula and optionally salts thereof:

wherein R₁ is C_(n)H_(2n+1), wherein n=0 to 12; benzyl; acrylate; or H; wherein R₂ is C_(n)H_(2n+1), wherein n=1 to 22; wherein X═Cl, Br, or I. 